Carton



B. J. DAVIDSON Jan. 23, 1945.

CARTON Filed March 14, 1942 3 Sheets-Sheet 1 INVENTOR BRUCE J; DAV/050A!BY Aorm Jan. 23, 1945- B; J. DAVIDSON CARTON Filed March 14, 1942 3Sheets-Sheet 2 INVENTOR B. J. DAVIDSON Jan. 23, 1945 CARTON 3Sheets-Sheet 3 INVEN QR BRUCE Ll. DAV/0S0 Filed March 14, 1942 PatentedJan. 23, 1945 Bruce J. Davidson, Manhasset, N. Y., 'asslgnor to NationalBiscuit Company, New York, N. Y., a

corporation of New Jersey Application March 14, 1942, Serial No. 434,719

6 Claims.

My invention pertains to cartons and has for its principal object toreduce to a minimum the amount of material needed to make a carton ofgiven size, and not decrease its strength or case of fabrication, andyet produce a carton that-can be made on existing machines with onlyslight or no adjustments or alterations and by well known methods.

Another object is to produce cartons, from heavy material such ascorrugated board and the like, suitable for use as shipping containers,and from light material such as chipboard, suitable for small packages,that will use a minimum of material, yet retain all the advantages of.the common forms of cartons that use more material.

Another object is to produce an easy opening and re-closable cartonusing a minimum of material.

Another object is to form and proportion the closing flaps on cartonblanks so that they will interlock with flaps of adjacent blanks andeliminate substantially all waste and can be cut from a continuous sheetor roll or material.

The above and other objects and advantages are attained by my invention,attention being directed to the accompanying drawings wherein I haveillustrated how it may be adapted to containers of different kinds.

Fig. 1 is a plan view of a sheet of material, as

corrugated or heavy board, from which blanks for two cartons orcontainers may be out without waste and with a minimum 01' material.

Fig. 2 shows an empty carton, open at both ends, formed from one of theblanks of Fig. 1.

Fig. 3 shows the carton filled and closed.

Fig. 4 is similar to Fig. 1 showing a carton in which the top closingflaps are stepped and wide enough to provide a center overlap when thecarton is closed.

Fig. 5 shows an empty carton formed from a blank of Fig. 4.

Fig. 6 shows the carton filled and sealed.

that may be cut from a continuous roll or sheet of material.

Fig. 13 shows an empty carton, open at both ends, formed from a blank ofFig. 12.

Fig. 14 shows the carton of Fig. 13 filled and sealed.

Fig. 15 shows the carton of Fig. 14 after it has been opened andreclosed.

Figs. 16 and 17 show a carton made ironi s. single piece blank havinganother form of top closing flaps made according to my invention.

In Fig. 1, I have shown a rectangular sheet of cardboard, corrugatedboard or other similar material, which is scored and cut to form twoidentical carton blanks. In making cartons from material of this kind,the sheets are made of such size as to enable 2, 3, 4, or more blanks tobe cut therefrom without excessive waste, that is,

so that the four edges of the sheet rorm edges of the carton blanks.

Heretoi'ore, carton blanks cut from these sheets have had all theclosing flapsrectangular, with the outer closing flaps, both top andbottom, of

a width equal to one-half the width of the carton when the edges of theflaps are to abut or meet at the center, and this width plus one-halfthe over-lap when the flaps are to be overlapped in the closed carton.In such cases, the inner end closing flaps are made the same width asthe outer closing flaps because the size of the sheet would not hereduced by cutting them of! shorter. Such a carton blank is shown, byway of comparison in Fig. 11.

In Fig. 1, each carton blank has two side panels 20, 2|, and two endpanels 22, 23, which are Joined by score lines 24, 25, 26, along whichthe material Fig. 7 shows how the carton blanks may interlock and be cutfrom a continuous sheet or roll without substantial waste.

Fig.8 shows an empty carton formed from a blank of Fig. 7.

Fig. 9 shows a carton of Fig. 8 filled and sealed. Fig. 10 shows thecarton re'closed after having been opened. 5

'Fig. 11 shows by way of compariso'n how carton blanks were out prior tothe present invention.

Fig. 12 shows another'blank for forming a reclosable carton, embodyingthe present invention.

is folded to form the carton. The meeting edges 21, 28 are secured as bya tape 29, Fig. 2.

A longitudinal score line 30, defines one edge of the side and endclosing flaps 3|, 32, 33, 34, which are rectangular and or a width equalto one-half the width oi. the end panels 22, 23. This is theconstruction usually used prior tothe present invention. Theserectangular-flaps could be cut: the same shape as those on'the oppositeside of the panels but to do so would not save any usable material,because the material cut off would be useful only as scrap and the totalsize or area or the sheet would not be reduced. This is true only whenthe closing flaps come to the.

naps of two blanks can abut or interlock within I I the area or thesheet, then a saving in material is effected. 4

A longitudinal score line 35, along the opposite edges of the side andend panels defines one edge of the closing flaps 36, 31, 38, 39, whichare trapezoids, the widest dimension X of which is a function of the.length and width of the carton and the minimum allowable width of theinner closing flaps.

The flaps 31, 39 are the inner or end closing flaps because they areturned in first and then the outer or side flaps 36, 38 are turned downand secured over them. The narrowest or minimum allowable width Q ofthese inner flaps is one of the i actors or variables which governs thegreatest width X of the outer flaps 36, 38.

When the flaps 36, 38 are to meet or abut at the center, as shown inFig. 3, then their width at the center equals where W equals the widthof the end panels. If L equals the length of the carton, or side panels,then the maximum width X of the top closing becomes a function of W, Land Q, and may be expressed by the equation X=F (WL-Q) Usually W, L andQ will be known for any specified container. Thus, a corrugatedcontainer for holding 6 No. 10 cans of biscuit, fruit, paint or othermerchandise, would be 12 /2 in. wide,

18%; in. long and 'l in high, i. e., W=12 and 'L=l8 The width of theinner flap at its narrow end is governed by the nature of the material.With corrugated board, or other board suitable for shipping containers,this dimension Q is 1% in.

Knowing these factors, L, W and Q, it becomes a simple mathematicalproblem to determine the maximum width X of the outer flaps and hencethe minimum amount of material to be used per carton.

Referring now to Fig. 1, the line a, b, is drawn parallel to the basesof the flaps 36, 31. This divides the two flaps into two similartriangles abc and ade and a rectangle abfg.

In the triangles Since the triangles are similar From which The value ofX may also be determined graphically. Knowing the values of W, L and Q,the perpendicular lines do and of may be laid 01! equal to Q and L-i-W,respectively, and the point e determined by erecting the pe pendicularde, equal to at a distance equal to from point i. Then, a line drawnthrough a and e will intersect the perpendicular fc at a point such thatis will equal X. This graphic method usually will be used in laying outthe cartons and locating the positions of the cutters. However, themathematical determination is useful in calculating the saving inmaterial. Thus, in the layout shown in Fig. 1, the saving in materialfor each container is the difierence between the areas of the flaps 3|,32, 33, 34 and the flaps 36, 31, 38, 39. If the material be such thatthe cartons can be cut from a continuous sheet, then.

the saving is doubled.

Considering again the carton for 6 No. 10 cans, the area of the flaps3|, 32, 33, 34 is Now in the case of flaps 36, 31, 38, 39, theirarea=(X+Q) (L-l-W) =(8.25+1.5) 31=302.87.

Thus, the saving per carton, when only one end is provided with thediagonal closing flaps is 387.5-302.87=84.63 sq. in. or 21.8% of theusual flap area. If the cartons can be cut from a continuous sheet sothat both ends may have my improved flaps, then double the area issaved.

When the carton flaps have anoverlap, instead of abutting as shown inFigs. 1 and 3, then the width of the outer flaps 36, 38 is increased byan average of one-half of the overlap, but the minimum width Q of theinner flaps is not changed. Thus, if the overlap is 1 inches, then theaverage increased width of the outer flaps will be /4 inch. The totalsaving in square inches of material will be approximately the same aswith abutting flaps.

In Figs. 4 to 6, I have shown my present invention embodied in the samesize carton as in Figs. 1 to 3, but with the top closing flaps wideenough so that they overlap at their free edges, yet without increasingthe width Q of the inner end closing flaps beyond the allowable minimum.

In Fig. 4, the sheet of material as corrugated board, sufiicient to formtwo blanks, is cut and scored to form the side panels 40, 4| and endpanels 42, 43 with the usual rectangular closing flaps 44, 45, 46, 41 onone side and polygonal closing flaps 48, 49, 50, 5! on the other side.The minimum width Q of the inner closing flaps 49, 5| is retained at 1/2 inches, the same as in Fig. 1 for a carton of the same dimensions,but the maximum width X of the outer closing flaps 43, 50 is increasedenough to give an overlap of 1 inches, but this dimension X in Fig. 4,is somewhat less than dimension X in Fig. 1 plus onehalf of the overlap.Thus, the lay-out of Fig. 4 saves more material, with or without anoverlap, than does the lay-out of Fig. 1, with the same or no overlap.

The width of the flaps 44, 45, 4B, 41 is equal to one-half the width ofthe carton plus one-half the overlap.

In Figs. 4 and 6, L, W and Q equal the length and width of the cartonand minimum allowable width of inner flaps, the same as in Fig. 1. Xequals the maximum width and Y the minimum width of the outer closingflaps, and P equals the overlap of the top flaps. In all cases, L, W, Qand P will be known and usually Q and P will be equal or 1 inches in theexample chosen. As seen in Fig. 6, X+Y=W+P. From Fig. 4, X+Q=2Y, or

X+Q Y 2 From this,

X X+ Q W P, clearing of fractions From this it is seen that X is afunction of W and Q, or W and P.

X+ Y: W+ P= W+ Q, substituting the value of X,

Consider now a carton of the dimensions previ- *ously considered, thatis 12 /2 x 18 /2 inches, with a minimum flap width of 1 /2 inches and anoverlap of 1 /2 inches, then the area of flaps 48, 49, 60, 56 is(l2.5+l8.5) =10.333X 31=320.3 3

square inches. The area of the rectangular flaps is The saving percarton, when the flaps on one only are made according to this form of myinvention is 434-320.3=113..7 sq. in. This is a saving of 26.2% of thematerial that heretofore has gone into the closing flaps.

The small triangular pieces 52, Fig. 4, may be of therectangular part ofwidth Y is L-W, and

1 I prefer to make the length of the rectangular when the blank isfolded to form a carton,

the meeting edges of the panels 40, 43 may be secured by a tape, ormetal clip 54 or other suitable means. When the cartons are made fromsuitable material, the free edge of either of the panels 48, or 43, mayhave a glue strip formed integral therewith which will be glued orstapled to the free edge of the adjoining panel when the carton isformed.

In Figs. '7 to '10, I have illustrated a reclosable carton madeaccording to the present invention that maye be out from a continuoussheet or'roll of chip board, or other suitable material, and effect asaving in material similar to the two forms previously described.

- In Fig. '7 I show part of a continuous sheet or roll of material fromwhich the carton blanks are being cut out. Two full carton blanks andparts of two adjoining blanks are shown. Each blank has twoside panels55, 56 and two end panels 51, 58 joined together along the usual scorelines. A glue strip 59 is formed on one blank attached to the free edgeof end panel 58. On the adjacent blank, this strip is attached to sidepanel 55. This is done so that all glue strips are cut from the sameedge of the material and the only waste is the narrow strips 60 betweenadjacent glue strips 59. When the blanks are cut from a continuous sheetor roll, as here shown, both top and bottom closing flaps can be cut soas to eifect double the saving in material over Figs. 1 and 4.

The side panels 55, 56, have top closing flaps 6|, 62 and bottom closingflaps 63, 64, respectively, joined to them along the usual score or foldlines. These closing flaps are of Stepped formation similar to those ofFig. 4, except that the corners of the Wide part of the flaps,correspondcut out and discarded, in which case the inner ing totriangles 52, are out off only on the flap, as 62 or 64, that is last tobe folded down when the carton is closed at top or bottom. Each endpanel 51, 58, has top. and bottom inner flaps- 65, 65, 61 and 68, all ofwhich are of the same size and shape.

The flaps 62, 64, are closed last at the top and bottom respectively, ofthe carton. These flaps are wide enough to overlap the flaps 6|, 63 andbe glued to them, as shown in Fig. 9. In order to avoid having a squarecorner on the flap in the middle of the top and bottom, which would beadapt to catchon similar corners of stacked cartons, I cut off thecomers of these flaps, as shown at 68. This leaves the triangles 10 thatcould be left attached to the inner flaps 65, 61, but I prefer to cutthem off as scrap and leave all the inner flaps identical. The topclosing flap 6| has a short slit 1| which receives and forms a lock withthe diagonal edge 69 of the opposite flap 62, when the carton isreclosed, as shown in Fig. 10.

In forming a carton from a blank of Fig. 7, the blank is folded alongthe score lines so that the free edges of panels 55 and 58 are broughttogether and secured by the strip 59, which will be glued or otherwisefastened to the face, inner or outer, of the adjacent panel. In Fig. 8,I show a carton partly, formed with the strip 59 integral with panel 58and glued to the inner face of panel 55. The next operation is to turnin the two inner bottom flaps 61, 68. The flap 63 is next turned downand glued to flaps 81, 68. Flap 64,

which may have a clipped corner 69, is then turned down and glued toflaps 83, 61 and 68. Flap 64 overlaps flap 63 an amount sufiicient tomake a secure joint.

After the carton is filled, the flaps 65, 66 and 6|, 62, are turned downand sealed in the same manner. The flap 82 overlaps the flap 6|, asshown in Fig. 9 which illustrates the carton filled and sealed ready forshipment.

The carton of Fig. 9 may be opened and reclosed as shown in Fig. 10. Toopen the carton, the point of a kitchen knife or other flat instrumentmay be inserted at the diagonal edge 88 between the fiaps 6|, 62 andpushed along, each way, to break the seal between them. The seal betweenthe top flaps and the inner flaps 65, 66 may be similarly broken. Thisreleases all flaps without destroying any of them, and the carton can beopened to give access to its contents by turning the flaps up tovertical position.

To reclose the carton, the overlap or lip 12 of flap 62 is tucked underflap 6| so that the inclined edge 69 enters into the slit H as shown inFig. 10. This holds the carton closed until the consumer again wishes touse some of its contents. When reclosed, the edge of the wide part ofeach flap lies under the narrow part of the opposite flap.

In Fig. 12, I show another blank for a reclosable carton embodying myinvention that may be cut from a continuous sheet of material, the flapsof adjacent blanks interlocking and one corner of the outer or free edgeof each flap being cut away so that they will not overlap at the edgesand the filled carton will stand firmly on a sealed end.

I show one complete blank and part of an adjoining one with their flapsinterlocking. Each blank has formed thereon two end panels 12, 13, whichalternate with two side panels H, I5, separated by score lines 16, I1,18, on which the material is folded to form the carton. A glue strip 18is attached to the free edge of one of the end or side panels along ascore line 80, and is adapted to secure the meeting edges of the panels12 and 15. v

At the top of the respective panels are end or inner sealing flaps 8|,82 and side or outer sealing flaps 83. 84, the flap 83 having a slit 85similar to the slit H in Figs. 7 to 10. The corner 86 of the wide end offlap. may be cut away found desirable. However, one reclosable endusually is'sufiicient.

The flaps 33, 84 add 89, 9|), like the flaps in Figs. 4 and 7 are widerat one end than the other and are wide enough to overlap at their inneredges. As shown in Fig. 6 where these flaps overlap at 9|, 9| at theends of the carton, and in Fig. 9 at 82, 92' there are three thicknessesof. material which form somewhat of a ridge at this point. This is notobjectionable when the on end. In order to make this sealed end flat andavoid this triple thickness, I cut out the free corners of the narrowends of the outer flaps at 93, 94 and 95, 96, so that when the carton issealed, as in Fig. 14, the edges of these out out portions will abut theedge of the wide parts of the opposed closing flaps and not overlap it.Thus, over the greater part of the width of the flaps 8|, 82 and 81, 88and close to the end panels where the sealed top is rigid, it is smooth,and the carton when stood on end has a firm bearing throughout thisarea. This feature or advantage is equally applicable to the cartons ofFigs. 4 to 6 and 7 to 10, and to the cartons of Figs. 1 to 3, if it hasoverlapping flaps. The carton of Fig. 15 may be opened and reclosed inthe same way as in Fig. 10.

When carton blanks are to be made, as in Fig. 4. but without overlap ofthe flaps 48, 50, then When cartons are to be made as in Figs. 1 to 3,but with the flaps 33, 38 overlapping, then the point C or dimension Xwill be determined by increasing the dimension by one-half of theoverlap, that is the point e will be raised by The dimension Q and thepoint a will remain the same. A line drawn from a through the newposition of e will determine the length of X at the point where itintersects the line 10.

In Fig. 11, I have shown a sheet just large enough to out two cartonsaccording to the best practice prior to my invention, the cartons beingidentical in siz with those shown in Fig. 1. In Fig. 11, I have markedthe several parts with the same relative reference numbers for easycomparison with Fig. 1 and their description need not be repeated. Inthis figure, W and L are identical with the same dimensions in Fig. 1.and the flaps 3| to 34' on the two edges of the sheets are the same asflaps 3| to 34, the width of each being cartons are relatively wide andnot very tall. But when the cartons are relatively tall and narrow as inFigs. 12 to 15, this ridge would make them unstable and prevent theirbeing stacked This is according to the most economical and best practiceprior to my present invention; The length of the total sheet in Fig. 11'is identical with the length of the sheet in Figs. 1 and 4, but thewidth is greater. This shows graphically the saving ,in materialaccomplished by my invention, even though the flaps on only one end ofthe carton be made according thereto. On Fig. 11, the material below thedotted line A-B is in excess of the material required to make cartons ofidentical dimensions in Fig. 1. If the cartons can be out continuouslyfrom along sheet or roll, as in Figs. 7 and 12. the saving is doublethis amount, and when the closing flaps are of the shape shown in Figs.7, 12 and 16, the saving is'even greater.

In Figs. 16 and 17, I show a carton made from a blank similar to Fig. 4,except that the outer closing flaps overlap for only a ,part of theirlength. The blank is folded to bringits two edges together when they aresecured as by a tape 91. The lower end of the carton may beclosed by theusual rectangular closing flaps, of which only two 98, 99 are visible,but these flaps may be cut the same as those at the top, if desired, orif the size of the sheet from which the blanks are cut is large enoughto let the flaps on adjacent blanks interlock, as in Figs. 7 and 12. q

At the top, the inner fiaps i011, ,IOI are cut rectangular, and thewidths of the outer closing flaps I02, 13 is such that they abut, orsubstantially abut, at their two ends, but have an overlap I04 betweenends or at or near the center of the top. The flaps I02, I03 may besecured to the inner flaps 590, l ill by stapling, gluing or othersuitable means. The overlapping parts I04 may be secured togethersimilarly. This form of the invention provides a carton having a topthat is smooth at the ends so the cartons can be stacked and can be usedin all cases where the carton does not have to be sealed tightly. Bysecuring the flaps together at H04, it is not necessary to use tape toclose the joint and hold the flaps I02, I03 together at the center.

Many other variations, adaptations and modifications of my invention canbe made, but the foregoing illustrations seem to be sufiicient toindicate its scope and not to limit it.

While I have shown the cut-out corners 93, 94

only in Figs. 12 to 15, this same principle or element is equallyadapted to flaps as shown in the other figures when an overlap is notdesired at the edges of the carton. I have shown cartons that areadapted to be closed by taping, gluing, or

- stapling, but it is within the contemplation of my invention that theouter closing flaps may be provided with interlocking tongues and slits.Also any of the cartons illustrated may be secured together by tapes 29,56, as shown in Figs. 2, 5 and 16, or by stapling or glue strips 59, 19,as shown in Figs. 8 and. 13.

In all of the embodiments of my invention illustrated the saving inmaterial is substantially the same as in Figs. 1 and 4, and may bedetermined by similar formulae and computations. The cartons of Figs. 7to 15 are adapted to be made from thin chipboard and used for packaginglight materials, as cereals, crackers, and the like. When so made andused, the width Q of the inner flaps may be from %-to 1 inch. In allforms of the invention, the closing flaps on adjacently formed blanksinterlock or interfit without waste of material, although the smalltriangles52, l0 and the like, may be. out 01f as scrap.

In describing my invention, the terms side and side panel are used todesignate the area having the longer horizontal dimension of the carton,whilethe terms end and end panel designate the area having the shorterhorizontal dimension. Therefore the length of the carton refers to itslonger horizontal dimension and the width of the carton is itsshorter-horizontal dimension, except in those cases where the two areequal.

panels and two side panels formed alternately thereon adapted to formthe four sides of the-carton, closing flaps attached to the top edges ofsaid panels, the flaps attached to the side panels being wider than theflaps attached to the end panels and adapted to overlie the latter whenthe carton is formed and closed, said side closing flaps being wider atone end than the other, the free edges of the wider and narrower partsbeing parallel to the opposite edge that is attached to the side panel,said flaps on adjacently formed blanksinterfitting without waste ofmaterial with the narrow part of a side closing flap abutting the narrowpart of a side closing flap on an adjacent blank and the wide part of aside closing flap abutting an end panel flap on the adjacent blank.

2. A carton having two opposite end panels and two opposite side panels,and flaps attached to the top edges of the end panels and outer closingflaps attached to top edges of the side panels, the end flaps beingnarrower than the outer closing flaps and lying within the latter whenthe carton is closed, the said outer closing flaps being of differentwidths at their two .ends and overlapping at their free edges when thecarton is closed with the wideend of each flap opposite the narrow endof the other, one of said closing flaps having a slit extending from itspart of less width into its part of greater width into which the edge ofthe widest part of the opposite flap may be inserted when the carton isreclosed In Fig. 1,'the triangular or sloping part of the end flaps 311,39 may be cut ofi so that these flaps will be rectangular and of uniformwidth Q, the

same as the triangular pieces 52, Fig. 4. In referring to the width Q ofthe inner flaps, this minimum width is intended.

What I claim is:

1. A blank for forming a carton having two end after having been opened.

3. A carton having two opposite end panels and two opposite side panels,end flaps attached to the top edges of the end panels and outer closingflaps attached to top edges of the side panels, the end flaps beingnarrower than the outer closing flaps and lying within the latter whenthe carton is closed, the said outer closing flaps being of difierentwidths at their two ends and overlapping at their free edges when thecarton is closed with the wide end of each flap opposite the narrow endof the other, a notch substantially equal to the overlap being cut inthe outer edge of the narrow end of each outer flap where it overliesthe end flap, whereby the outer flaps will abut at the edges of thecarton.

4. A carton having two opposite end panels and two opposite side panels,end flaps attached to the top edges of the end panels and outer closingflaps attached to top edges of the side panels,

the end flaps being narrower than the outer closing flaps and lyingwithin the latter when they carton is closed, the said outer closingflaps being of different widths at their two ends and overlapping attheir free edges when the carton is closed with the wide end of eachflap opposite the narrow end of the other, the overlap being cut away atthe ends of the outer flaps, whereby these flaps will abut the edges ofthe carton.

5. A carton formed from a blank having two side panels and two endpanels formed alternately thereon, a glue strip formed integral with thefree edge of one side panel and secured to the free edge of an adjacentend panel, end flaps attached to the top edges of the end panels andouter closing flaps attached to the top edges of the side panels, theend flaps being narrower than the outer closing flaps and lying underthe latter in the closed carton, the said outer closin flaps beingofdifierent widths at their two ends and overlapping at their free edgeswith the wide end of each flap opposite the narrow end of the other, theoverlap being cut away. at the ends of the outer flap by a notch formedin the edge 'of the narrow end of each flap of a width equal to saidglue strip and the part so cut out to form the notch forming an integralpart of the wide end of anouter flap on an adjacently formed blank.

6. A carton that is out and scored to form alternately two side and twoend panels, the side panels being longer than the end panels, closingflaps attached to the top edges of said side CERTIFICATE OF CORRECTION.

Patent No. 2,567,717.

January 5, 9 5- BRUCE J. DAVIDSON.

It is hereby certified that error appears in the printed specificationof the above numbered patent requiring correction as follows: Page 5,second column, line 60, claiml after "abut" insert the word --at--; page6, first column, line 6 claim 6, after "carton" insert --blank---; andthat the said Letters Patent should be read with this correction thereinthat the same may conform to the record of the case in the PatentOffice.

Signed and sealed this 5th'da of June, A. D. 19L 5.

Leslie Frazer dieting Commissioner of Patents.

